A couple of years ago I repaired the doors on my coach. They were damaged because rain water entered the core of the door through the latches. When the water froze -40 in our area at the coldest. The expansion damaged the door outer skin. No damage to the inside but cosmetically it looked terrible. I bought the unit like this and was not concerned with the damage.

I contacted the company that made it and they said that they should have had drains holes in the doors. However they were overlooked at the time of construction.
That was 18 years ago so no big deal. I drilled holes as per the factory rep. Good fellow very helpful.
So once I was assured that the problem would no longer be an issue, I started to look at a fix.

One picture shows the damaged door before I started the repairs.
Picture 2 Damage
Picture 3 Close up of damage.
Picture 5 Repair in progress. Also you can see the new drain hole bottom right of the door.
Final Picture of job completed and repainted.

The repair process.

In Picture 3 you can see the damage better. What I did was peel back the skin and with a blow gun and lots of pressure I blew out the foam core around the damage. It was like blowing out popcorn as the foam had deteriorated over the years. But this was just around the damage. The rest of the door was in excellent shape. Once the door was repaired I inserted a long nozzle off an expanding foam bottle through the drain holes that I made. Filled the damaged areas and proceeded with the skin repair.

To repair the skin I took my orbital sander and with a 80 grit sandpaper I dished out the damaged area.
I then applied fibreglass cloth and epoxy to the repair. I used a little body filler to smooth out the repair.

I repainted the whole lower skirt with 2 part Plastic Paint. (not epoxy paint) I painted my air plane with this paint and the Canadian Air force has used this paint on a F-18.

This whole repair was made out side in the spring. I had one bug that I had to remove after the paint dried.

I am very pleased with the results. Just thought somebody else might need this type of repair.

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